Machine and methods for forming, erecting, and loading a pouch with a product

ABSTRACT

A transport mechanism for engaging a pouch in an erect configuration at a first station of a packaging machine and transferring the pouch to a second station of the packaging machine includes a carriage and a grip assembly. The carriage is moveable between the first station and the second station. The grip assembly is coupled to the carriage and is at least partially moveable relative to the carriage between an engaged position for clamping the pouch in the erect configuration within the grip assembly, and a released position.

BACKGROUND

This disclosure relates generally to packaging, and more particularly toa machine for forming, erecting, and loading a package with a productfor shipping such as in an e-commerce environment.

Shipping needs for e-commerce and the like include considerable volumeof packaging used for shipping products. Multiple items can be groupedin a single order, but in order to economize and ship the productstogether, they must be packaged together in a single sipping container.In other cases, a single product such as a book may be shipped on itsown, but it needs a shipping package or container to protect it duringtransit. Fulfilment centers where products are placed in shippingcontainers match orders with one or more products by size to anappropriate shipping container. Given the large variation in order andproducts sizes, there must be a large variety of shipping containers instock. Systems that provide custom-sized shipping packages on an orderby order basis can considerably reduce the complications in fulfilmentcenters. The conventional techniques have been considered satisfactoryfor their intended purpose. However, there is an ever-present need forimproved packaging systems and methods. This disclosure provides asolution for this need.

BRIEF DESCRIPTION

In one aspect a transport mechanism for engaging a pouch in an erectconfiguration at a first station of a packaging machine and transferringthe pouch to a second station of the packaging machine is provided. Thetransport mechanism includes a carriage and a grip assembly. Thecarriage is moveable between the first station and the second station.The grip assembly is coupled to the carriage and is at least partiallymoveable relative to the carriage between an engaged position forclamping the pouch in the erect configuration within the grip assembly,and a released position.

In another aspect a packaging machine is provided. The packaging machineincludes a first station for receiving a container in an erectconfiguration and a second station spaced from the first station. Thepackaging machine further includes a transport mechanism for engagingthe container in the erect configuration at the first station andcarrying the container to the second station. The transport mechanismincludes a carriage that is moveable between the first station and thesecond station and a grip assembly coupled to the carriage. The gripassembly is at least partially moveable relative to the carriage betweenan engaged position for clamping the container in the erectconfiguration within the grip assembly, and a released position.

In yet another aspect, a method of assembling a pouch is provided. Themethod includes receiving a pouch in an erected configuration at a firststation of a packaging machine and moving a transport mechanism to thefirst station. The transport mechanism including a carriage and a gripassembly couped to the carriage. The method further includes clampingthe pouch within the grip assembly by moving at least a portion of agrip assembly relative to the carriage and carrying, by the transportmechanism, the pouch from the first station to a second station of thepackaging machine.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an example embodiment of a packagingsystem according to the present disclosure.

FIG. 2 is a perspective view of an embodiment of a flattened tube ofstock packing material for the system of FIG. 1 .

FIG. 3 is a perspective view of a portion of the system of FIG. 1 ,showing a cutting station, a filling station, a sealing station, and anoutput conveyor.

FIG. 4 is a perspective view of filling station shown in FIG. 3 .

FIG. 5 is a perspective view of the filling station and the sealingstation shown in FIG. 3 .

FIG. 6 is an enlarged view of the filling station shown in FIG. 3 .

FIG. 7 is a perspective view of the output conveyor shown in FIG. 3 .

FIG. 8 is a schematic view of a grip assembly for use with the systemshown in FIG. 3 , showing the grip assembly in a released state.

FIG. 9 is another schematic view of the grip assembly shown in FIG. 8 ,showing the grip assembly in an engaged state.

FIG. 10 is an enlarged view of the filling station shown in FIG. 3 ,showing a first step of filling a pouch-preform.

FIG. 11 is another view of the filling station shown in FIG. 10 ,showing a second step of filling the pouch-preform.

FIG. 12 is another view of the filling station shown in FIG. 10 ,showing a third step of filling the pouch-preform.

FIG. 13 is another view of the filling station shown in FIG. 10 ,showing a fourth step of filling the pouch-preform.

FIG. 14 is another view of the filling station shown in FIG. 10 ,showing a fifth step of filling the pouch-preform.

FIG. 15 is another view of the filling station shown in FIG. 10 ,showing a sixth step of filling the pouch-preform.

FIG. 16 is another view of the filling station shown in FIG. 10 ,showing a seventh step of filling the pouch-preform.

FIG. 17 is an enlarged view of the sealing station shown in FIG. 3 ,showing a first step of sealing a filled pouch.

FIG. 18 is another view of the sealing station shown in FIG. 17 ,showing a second step of sealing the filled pouch.

FIG. 19 is another view of the sealing station shown in FIG. 17 ,showing a third step of sealing the filled pouch.

FIG. 20 is another view of the sealing station shown in FIG. 17 ,showing a fourth step of sealing the filled pouch.

FIG. 21 is another view of the sealing station shown in FIG. 17 ,showing a fifth step of sealing the filled pouch.

FIG. 22 is another view of the sealing station shown in FIG. 17 ,showing a sixth step of sealing the filled pouch.

FIG. 23 is another view of the sealing station shown in FIG. 17 ,showing a seventh step of sealing the filled pouch.

FIG. 24 is a perspective view of the pouch of FIG. 23 , showing thepouch closed with product therein, and labeled for shipping.

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like referencenumerals identify similar structural features or aspects of the subjectdisclosure. For purposes of explanation and illustration, and notlimitation, a partial view of an embodiment of a system in accordancewith the disclosure is shown in FIG. 1 and is designated generally byreference character 100. The systems and methods described herein can beused to package products within bespoke or custom sized mailers for eachorder being shipped. The system 100 includes a cutting station 102, aproduct conveyor 104, a filling station 106 (also referred tointerchangeably herein as an “erecting station,” a sealing station 108,and an output conveyor 110. In other embodiments, the system does notinclude product conveyor 104.

In the example embodiment, cutting station 102 includes a tube conveyor112 for conveying a flattened tube 114 of stock packing material from asupply 107 in the form of a fan-folded bale. The tube conveyor 112includes an opposed pair of rollers (not shown) that roll the tube 114therebetween to advance the tube 114 down a slide 116. A separator 118is operatively connected to the tube conveyor 112 for receiving an endof the flattened tube 114. The tube conveyor 112 is configured to feed acustom length of the tube 114 into the separator 118. A an x-y arraysensor system 122 is operatively connected to the product conveyor 104to measure custom orders of product 120 passing through the sensorsystem 122 on the product conveyor 104, provide measurement input to acontroller 125 that is connected to control the tube conveyor 112 andseparator 118 to separate the custom length of the tube 114 to fit eachcustom order of product 120. Those skilled in the art will readilyappreciate that the any suitable sensor system can be used in additionto or in lieu of sensor system 122, e.g. an imaging device with animaging processing module for determining the size of product 120passing through the field of view, can be placed further upstream thandepicted in FIG. 1 without departing from the scope of this disclosure.It is also contemplated that in addition to or in lieu of the sensorsystem 122, any other suitable type of sensor system can be used, suchas devices that measure by physical contact, or that known dimensionsfor products traveling in order on the product conveyor 104 can beprovided from a database (not shown) operatively connected to controlthe tube conveyor 112 and separator 118 without making measurements.

The separator 118 is configured to separate the custom length of thetube 114 from the tube 114 for each respective product 120 arriving onthe product conveyor 104 to form a custom sized pouch pre-form 132 thatcan differ for each individual pouch pre-form 132. FIG. 2 shows the end105 of the tube 114. The two parallel, opposed edges 126, 128 areoverlapped and adhered together to form a seam 130 in a first panel 133of the tube running along the tube 114 in a longitudinal direction L. Inits flat state as it arrives at the conveyor 112 from the supply 107, asshown in FIG. 2 , the tube 114 includes lines of weakness 138, e.g.,score lines, for forming two opposed, pleated side panels 146 eachconnected to the first panel 133 along a respective fold line 134, 136.A seamless second panel 144 opposite the first panel 133 is connected tothe side panels 146 by fold line 140 and a line of weakness 138 forforming a fold line 142. The pleat lines 148 are formed by the remaininglines of weakness 138. In other embodiments, the pouch pre-form 132 maynot include the pleat lines 148. For example, in some alternativeembodiments the pouch pre-form 132 may be a non-rigid substrate that isprovided with two opposed score lines. In further alternativeembodiments, any suitable pouch-preform may be used in system 100.

Referring back to FIG. 1 , a first closer 150 is operatively connectedto the separator 118 of FIG. 1 to receive the pouch pre-form 132 andclose one end 152 of the of the pouch pre-form 132, leaving one end 154of the pouch pre-form 132 open. In the example embodiment, the firstcloser 150 includes vacuum suction cups (not shown) that are configuredto pull apart the end 152 for applying an adhesive therein and closingthe end 152. In other embodiments, the separator 118 and first closer150 may be substantially the same as the separator 118 and first closer156 described in U.S. Patent Application Publication No. 2020/0317383(“the '383 application”), the entire contents of which are herebyincorporated by reference. In particular, separator 118 and first closer150 receive the tube 114 as an input and cut and seal, respectively, aportion of the tube 114 to output the pouch pre-form 132 insubstantially the same manner as described with respect to FIGS. 2-8 ofthe '383 application. In other embodiments, any suitable separatorand/or first closer may be used.

The filling station 106 is provided downstream from cutting station 102.The filling station receives the pouch 132 (also referred tointerchangeably herein as a “container”) having an unsealed end 154(e.g., as shown in FIG. 6 ) to allow for filling the pouch with acorresponding product 120. In particular, the filling station 106 isoperatively connected to the first closer 150 (shown in FIG. 1 ) toreceive the pouch pre-form 132 and to present the unsealed end 154 ofthe pouch pre-form 132 for receiving orders of product 120.

Referring to FIGS. 3 and 4 , in the example embodiment the system 100includes a frame 160 that at least partially defines each of the cuttingstation 102, the filling station 106, the sealing station 108, and theoutput conveyor 110.

As shown in FIG. 4 , the filling station 106 includes a pivot shuttle156 configured to receive the closed end of the pouch pre-form (shown inFIG. 1 ) and flip the open end of the pouch pre-form away from the slide116, e.g. to face the unsealed end 154 of the pouch pre-form 132 towarda window 158 provided in the frame 160 at the filling station 106. Themovement of the pivot shuttle 156 is indicated in FIG. 4 by the largearrow, and is actuated by a linear actuator 211 (shown in FIG. 11 ),though in other embodiments any suitable actuator may be used.

The pouch pre-form 132 falls into the pivot shuttle 156 by the force ofgravity onto two fingers 162 provided on the shuttle 156. The fingers162 are attached to a belt driven actuator (not shown). As indicatedwith the curved arrow in FIG. 4 , the pivot shuttle 156 rotates about apivot under the force of the linear actuator (not shown) and then thefingers 162 move upward, pushing the pouch pre-form 132 upward towardthe window 158, as shown in FIG. 11 , and described in greater detailbelow.

Referring back to FIG. 1 , the product conveyor 104 conveys orders ofproduct 120 to the filling station 106. A user, and/or an automatedsystem, takes the product 120 from the product conveyor 104 and placesthe product 120 into open ends 154 of the pouch pre-forms 132 present atthe window 158 (shown in FIG. 4 ) of the filling station 106. The filledpouch 132 is then conveyed to the sealing station 108 for closing theopen end 154 of the filled pouch 132. A user, and/or an automatedsystem, then continuously repeats filling each pouch pre-form 132 oneafter another, and each custom sized pouch pre-form 132 is presented tothe user/system 100 when the corresponding order of product 120 arrivesat the user's end of the product conveyor 104. In other embodiments, thesystem 100 does not include the product conveyor 104. For example, insome such embodiments, the system 100 is configured to provide fixedsized pouch pre-forms 132 to the filling station 106 or a batch of sizescontinuously without a demand input from a product conveyor 104.

The system 100 further includes a clip conveyor 164 (also referred toherein as a “transport mechanism”) that carries the filled pouches 132from the filling station 106 to the sealing station 108. In particular,the clip conveyor 164 grabs the pouch pre-form 132 at the fillingstation 106 and holds the pouch pre-form 132 in an open, or “erect”configuration for receiving the product 120 therein. In the exampleembodiment, the product 120 is inserted into the pouch pre-form 132 by auser, though in other embodiments an automated system may be used. Thecontroller 125 is communicatively coupled to the clip conveyor 164(shown in broken line arrows in FIG. 1 ) and is configured to controltiming and operations of the clip conveyor 164, as described below ingreater detail, such that the clip conveyor 164 automatically engagesthe pre-form pouch 132 at the filling station 106 and holds the pouch132 at the sealing station 108 while an adhesive is applied.Additionally, the controller 125 may be further configured to controloperations and or timing of any of the components/mechanisms describedherein with respect to system 100.

Referring to FIGS. 5 and 6 , the clip conveyor 164 is operably coupledto one or more drives (not shown) for moving the clip conveyor 164relative to the frame 160. In particular, the conveyor 164 includes atrack (e.g., as shown partially in FIG. 17 ) provided on the frame 160and extending from the filling station 106 to the sealing station 108. Acarriage 168 of the conveyor 164 is moveable along the track 166 (shownin FIG. 1 ) in a machine transfer direction 170, indicated schematicallyby the large arrow in FIG. 5 . The clip conveyor 164 is configured forgenerally reciprocal movement along the machine transfer direction 170between the filling station 106 and the sealing station 108. Moreover,in the example embodiment, the machine transfer direction is generallytransverse to the direction of movement of the pivot shuttle 156 (shownin FIG. 4 ) and is also substantially transverse to a feed direction ofoutput conveyor 110 (shown in FIG. 1 ).

The clip conveyor 164 then carries the filled packages to the sealingstation 108 while a next pouch pre-form 132 is moved by pivot shuttle156 (shown in FIG. 4 ) towards the window 158. In the view shown in FIG.5 , the filled pouch 132 is in the open configuration at the sealingstation 108, while the carriage 168 is positioned at the filling station106. However, it should be understood that this view is for illustrativepurposes only and that, in normal operation of the example embodiment, afilled pouch 132 would not in the open configuration at the sealingstation 108 at the same time the clip conveyor 164 is at the fillingstation 106 (shown in FIG. 7 ).

Referring to FIG. 6 , in the example embodiment, the clip conveyor 164includes the carriage 168 and a grip assembly 172 coupled to thecarriage 168. The carriage 168 carries the grip assembly 172 duringmovement of the clip conveyor 164 to move the filled pouches 132 betweenthe filling station 106 and the sealing station 108 (shown in FIG. 5 ).The grip assembly 172 includes a plurality of rotatable rods 194, 196each having at least one clip 198, 200 (shown in FIG. 8 ) mountedthereon. Rods 194, 196 are each operably coupled to a rotation drive,such as a cam and piston drive (not shown), that is operable to rotatethe rods. In other embodiments, any suitable rotation drives may be usedto rotate the rods 194, 196.

Referring back to FIG. 5 , the sealing station 108 includes an adhesiveassembly 174 slidably coupled to frame 160. The adhesive assembly 174 ismoveable relative to the frame 160 in the machine transfer direction 170and is operable to apply a liquid adhesive to an inner surface 176 ofthe filled pouch 132. The sealing station 108 also includes a pair ofpressure bars 178 for closing the filled pouch 132 after the adhesivehas been applied, thereby sealing the product 120 within the filledpouch 132. In particular, the pressure bars 178 are each moveablerelative to the frame 160 and are moved toward one another to seal thefilled pouch 132. The pressure bars 178 may then be released, therebydropping the filled pouch 132 onto the output conveyor 110.

Referring to FIG. 7 , in the example embodiment, the output conveyor 110is positioned underneath sealing station 108, such that the filled pouch132 may drop from the pressure bars 178 (shown in FIG. 5 ) and slideonto the output conveyor 110 by an inner ramped surface 180 of the frame160. In the example embodiment, the output conveyor 110 is a beltconveyor, though in other embodiments, any other suitable conveyor maybe used. The output conveyor 110 moves the filled pouches 132 in a feeddirection 182 that is generally perpendicular to the machine transferdirection 170 (shown in FIG. 5 ). In particular, in the exampleembodiment, the feed direction 182 of the output conveyor 110 isgenerally opposite to a feed direction 183 of the tube conveyor 112(shown in FIG. 1 ). As a result, the pouch pre-forms 132 and filledpouches 132 are carried in a general U-shaped path from the tubeconveyor 112 at the cutting station 102 to an end of the output conveyor110.

FIGS. 8 and 9 show a schematic sectional view of the grip assembly 172of the clip conveyor 164 (shown in FIG. 6 ). The grip assembly 172 is atleast partially moveable relative to the carriage 168 between a releasedstate, as shown in FIG. 8 , and an engaged state for clamping the pouch132 within the grip assembly 172, as shown in FIG. 9 .

In the example embodiment, the grip assembly 172 includes a first grip184 for engaging a first side 186 of the pouch 132 and a second grip 188for engaging a second, opposed side 190 of the pouch 132. The first andsecond grips 184, 188 are configured to hold the pouch 132 in an openconfiguration at the filling station 106 to allow for loading of theproduct 120 into the pouch through the open end 154. The first grip 184and second grip 188 are spaced apart from one another in a closingdirection 189 to define a gap 192 therebetween, in which the pouch 132may received. In the example embodiment, the closing direction 189 issubstantially perpendicular to the machine transfer direction 170 (shownin FIG. 5 ).

The first grip 184 and second grip 188 each include a pair of rotatablerods 194, 196 which are rotatably coupled to the carriage 168 (shown inFIG. 6 ). At least one clip 198, 200 is coupled on each of the rotatablerods 194, 196 and is configured to rotate with the respective rod 194,196. In particular, the grips 184, 188 each include an inner clip 198coupled to a first rotatable rod 194 and an outer clip 200 coupled on asecond rotatable rod 196. The first rods 194 and inner clips 198 areeach positioned vertically above the respective the second rods 196 anouter clips 200. In the example embodiment, the first grip 184 and thesecond grip 188 are substantially identical and are mirrored about thegap 192, such that the clips 198, 200 all extend inward and towards theopposed clips 198, 200 of the opposed grip 184, 188. In otherembodiments, at least one of the first grip 184 and second grip 188 maybe different from one another. For example, and without limitation, insome embodiments, the first grip 184 includes a different number ofclips 198, 200 than the second grip 188.

The grip assembly 172 is transitionable between the released state andthe engaged state by rotating the rods 194, 196 of the first grip 184and second grip 188. Each of the rods 194, 196 are rotatable about arespective rotational axis R₁-R₄, extending into the page in FIGS. 8 and9 . In the example embodiment, each of the respective rotational axesR₁-R₄ of the rods 194, 196 are parallel to one another and are alsoparallel to the machine transfer direction 170 (extending into the pagein FIGS. 8 and 9 ). To transition from the released state to the engagedstate, the first rod 194 of the first grip 184 is rotated in a firstdirection (clockwise direction as shown in FIGS. 8 and 9 ) and thesecond rod 196 of the first grip 184 is rotated in a second direction(counter-clockwise direction as shown in FIGS. 8 and 9 ) that isopposite of the first direction. Additionally, the first rod 194 of thesecond grip 188 is rotated in the second direction and the second rod196 of the second grip 188 is rotated in the first direction. As aresult, as the rods 194, 196 are rotated to the engaged state, the clips198, 200 of the respective grips 184, 188 are brought into closeposition with one another to pinch the pouch pre-form 132 therebetween.Moreover, the grip assembly 172 is transitionable from the engaged stateto the released state in substantially the reverse manner as describedabove.

Referring to FIG. 9 , when the grip assembly 172 is in the engagedstate, the inner clips 198 of the first grip 184 and the second grip 188each contact an inner surface 176 of the pouch pre-form 132. Likewise,the outer clips 200 of the first grip 184 and the second grip 188 eachcontact an outer surface 177 of the pouch pre-form. The clips 198, 200each apply pressure on the pouch pre-form 132 such that pouch pre-form132 is pinched between the clips 198, 200 of the respective grips 184,188 and may be held in the open configuration, as shown in FIG. 9 .Accordingly, the grip assembly 172 is operable to support and carry thepouch pre-form 132 while holding the pouch pre-form 132 in the openconfiguration for inserting the product 120 and to allow for adhesive tobe applied on the inner surface 176, as described in greater detailbelow.

FIGS. 10-23 illustrate steps of the process of filling the pouchpre-form 132 with a product at the filling station 106 and sealing thefilled pouch 132 at the sealing station 108.

Referring to FIG. 10 , the pouch pre-form 132 is provided on the fingers162 of the pivot shuttle 156 at the filling station 106 and the window158 is closed. The frame 160 includes an interior surface 202 (alsoreferred to interchangeably herein as a “landing”) facing the pivotshuttle 156 for receiving the pouch 132. The system 100 further includesa pair of moveable guide paddles 204 (only one shown in FIG. 10 ) thatare selectively moveable relative to the interior surface 202 between aretracted position (as shown in FIG. 10 ) and an extended position (asshown in FIG. 11 ). The guide paddles 204 are spaced on the interiorsurface 202 to contact opposed sides of the pouch pre-form 132 when thepivot shuttle 156 is rotated (as shown in FIG. 11 ).

The filling station 106 further includes a plurality of moveable suctioncups 206, 208. A first side suction cup 206 is positioned within theframe and at least partially recessed relative to the interior surface202. The first side suction cup 206 is selectively extendable outthrough an opening 210 in the interior surface 202. A group of secondside suction cups 208 are spaced from the first side suction cup 206 andare oriented facing the first side suction cup 206. In the exampleembodiment, the system 100 includes one first side suction cup 206 andthree second side suction cups 208, though in alternative embodiments,any suitable number of suction cups 206, 208 may be used.

Referring to FIG. 11 , the pivot shuttle 156 is shown extended by theactuator 211 (e.g., along the arc as shown in FIG. 4 ). Duringoperation, when the pivot shuttle 156 is moved, the guide paddles 204are also extended outward from the interior surface 202 to guide thepouch pre-form 132 along the interior surface 202. The fingers 162 thenraise the pouch pre-form 132 on the interior surface 202 within thepaddles 204 until the pouch pre-form 132 is aligned with the opening 210and the first side suction cup 206 (shown in FIG. 10 ). The first sidesuction cup 206 is then actuated to provide a negative pressure on thepouch pre-form 132 and hold the pouch pre-form 132 in position on theinterior surface 202 and the guide paddles 204 are retracted back intothe interior surface 202. Additionally, the pivot shuttle 156 is movedback to the slide 116 (e.g., as shown in FIG. 4 ).

Referring to FIG. 12 ., the pivot shuttle 156 is shown being retractedback to the slide 116 and the second side suction cups 208 are moved toan extended configuration to contact the second side 190 of the pouchpre-form 132. The second side cups 208 are then actuated to provide anegative pressure on the second side 190 of the pouch pre-form 132.Referring to FIG. 13 , the second side suction cups 208 are then movedto a partially retracted position to provide the pouch pre-form 132 inthe open configuration.

Referring to FIG. 14 , with the pouch pre-form 132 in the openconfiguration, the carriage 168 is moved along the machine transferdirection 170 to the filling station 106 with the grip assembly 172 inthe released configuration and the clips 198, 200 aligned with the pouchpre-form 132. Referring to FIG. 15 , the grip assembly 172 is thenrotated to the engaged configuration, pinching the sides 186, 190 of thepouch pre-form 132 between the clips 198, 200 of the first and secondgrips 184, 188. Once the grip assembly 172 has secured the pouchpre-form 132, the suction cups 206, 208 are turned off and the secondside cups 208 are retracted from the second side 190 of the pouchpre-form 132. The window 158 is then opened (as shown in FIG. 16 , e.g.,by retracting or rotating the window 158), exposing the interior 212 ofthe pouch pre-form 132. The product 120 (shown in FIG. 1 ) may then beinserted into the pouch pre-form 132 by a user and/or an automatedmachine (not shown). After the product 120 is received within the pouchpre-form 132, the window 158 is closed and the carriage 168 is moved tothe sealing station 108 (as shown in FIG. 17 ).

In some embodiments, system 100 may include one or more sensors (notshown) for determining when a product 120 has been received in the pouchpre-form 132. For example, and without limitation, in some embodiments,the system 100 includes a scale (not shown) for measuring a weight ofthe pouch pre-form 132. In some such embodiments, the window 158 isclosed and the carriage is moved to the sealing station 108 in responseto the scale detecting a change in weight of the grip assembly 172 thatexceeds a predetermined threshold. In other embodiments, system 100includes one or more proximity sensors (not shown) that are operable todetect a product 120 entering the pouch pre-form 132.

Moreover, in some embodiments, system 100 further includes a sensor (notshown) operable to detect a position of the pouch pre-form 132 on theinterior surface 202. For example, and without limitation, in oneembodiment, system 100 includes a photosensor (not shown) that registersa position of the pouch pre-form 132 on the interior surface 202. Insome such embodiment, when the photosensor detects the presence of thepouch pre-form 132 on the interior surface 202 as being aligned with thevacuum cups 206, 208, the pouch pre-form is secured by the first sidecup 206 and the pivot shuttle 156 is moved back to the slide 116.

FIGS. 17-23 illustrate a process of sealing the filled pouch 132 at thesealing station 108. Referring to FIG. 17 , in the example embodiment,the carriage 168 is at the filling station 106, the pressure bars 178are positioned in a first separated position, and the adhesive assembly174 is in a retracted position. After the product 120 is received in thepouch pre-form 132, the carriage 168 is moved in the machine transferdirection 170 (shown in FIG. 5 ) to the sealing station 108, as shown inFIG. 18 . Referring to FIG. 18 , after the carriage 168 is moved to thesealing station 108, the grip assembly 172 and the filled pouch 132 areeach positioned laterally between each of the pressure bars 178. Theadhesive assembly 174 is then extended to position a nozzle 214 (shownin FIG. 19 ) of the adhesive assembly 174 within the pouch interior 212.In particular, in the example embodiment, the adhesive assembly 174includes a telescoping tip portion 216 that is selectively moveablebetween an extended position, as shown in FIGS. 18 and 19 , and aretracted position, as shown in FIGS. 17 and 21-23 .

The adhesive assembly 174 is also moveable along a track (not shown) tomove the adhesive assembly 174 in the machine transfer direction 170.For example, with continued reference to FIG. 18 , the adhesive assembly174 is simultaneously moved along the machine transfer direction 170 toa first end 218 of the filled pouch 132 while the tip portion 216 ismoved into the extended position. The adhesive assembly 174 thenselectively releases a liquid adhesive onto an interior surface 203 ofthe filled pouch 132 proximate the first end 218. As the adhesive isbeing released, the adhesive assembly 174 is moved in the machinetransfer direction 170 and within the pouch to a second end 220 of thefilled pouch 132, as shown in FIG. 19 . In the example embodiment, thetravel path of the adhesive assembly 174 is predetermined incorrespondence with the width of the filled pouches 132. In otherembodiments, system 100 may include one or more proximity sensors (notshown), configured to detect a position of the first and second ends218, 220 of the filled pouch 132 and the adhesive assembly 174 is movedbased on the detected positions of the ends 218, 220.

Referring to FIG. 20 , after the adhesive assembly 174 has deposited theadhesive on the interior surface 203 of the filled pouch 132, the tipportion 216 is retracted out of the pouch 132 and the grips 184, 188 areeach moved inward. In particular, in the example embodiment, the grips184, 188 are coupled to respective slidable frames 222, 224 that areeach moveable along a closing direction 189. The closing direction 189is generally perpendicular to the machine transfer direction 170 and tothe rotational axes of the rods 194, 196 (shown in FIGS. 5 and 8 ).Simultaneously and/or subsequent to the grips 184, 188 being movedinward, the pressure bars 178 are also moved inward to apply pressure onthe sides 186, 190 of the filled pouch 132 and seal the pouch 132closed. Additionally, the pressure bars 178 pinch the filled pouch 132to support the pouch 132 in position at the sealing station 108.

Referring to FIG. 21 , after the pressure bars 178 have engaged thepouch 132, the grips 184, 188 are moved away from one another back alongthe closing direction 189 and the pressure bars 178 continue to hold thefilled pouch 132 in position at the sealing station 108. The grips 184,188 are then rotated to the released position, as shown in FIG. 21 andthe carriage 168 is moved back to the filling station 106 to grabanother pouch pre-form 132, as shown in FIG. 22 . Referring to FIG. 23 ,after the carriage 168 has left the sealing station 108, the pressurebars 178 are retracted away from one another in the closing direction189, thereby releasing the filled pouch 132 onto the output conveyor 110(shown in FIG. 7 ). In some embodiments, the sealing station 108 furtherincludes one or more photosensors (not shown) for detecting whether thefilled pouch 132 is in position to allow for insertion of the tipportion 216 of the adhesive assembly 174.

With reference now to FIG. 24 , the closed pouch 132 complete with ashipping label 228 on the outside and product inside forms a mailer 226suitable for shipping in the mail or any suitable courier. The mailer226 is formed of a single piece of corrugated paperboard 230, or anyother suitable type of rigid tube form substrate such as solid fibercardboard, wrapped around product. Two parallel, opposed edges 126, 128(labeled in FIG. 2 ) of the single piece are adhered to one another toform a tube around an interior space for enclosing product. A first end244 of the tube is adhered to itself to enclose a first end of theproduct. A second end 246 of the tube opposite the first end of the tubeis adhered to itself to enclose a second end of the product.

The two parallel, opposed edges 126, 128 are adhered together to form aseam 130 in a first panel 133 of the tube along a first side of theproduct. The tube includes two side panels 146 each connected to thefirst panel 133 along a respective fold line 136,134. Each side panel146 extends from the first end 244 of the tube to the second end 246 ofthe tube. Each side panel 146 includes an inward pleat formed by a foldline or pleat line 148 extending parallel to the seam 130 from the firstend 244 of the tube to the second end 246 of the tube. In otherembodiments, the pouch 132 does not include the pleat line 148. Thoseskilled in the art will readily appreciate that the label 228 can beplaced on the opposite panel 144 (labeled in FIG. 2 ), instead of thefirst panel 133. The corrugation lines 232, only some of which areindicated in FIG. 24 , in the tube run lateral to the longitudinaldirection L of the seam 130 to facilitate forming the closures on theends 244 and 246 of the mailer 226.

Example embodiments of packaging machines are described above in detail.The packaging machines are not limited to the specific embodimentsdescribed herein, but rather, components of the machine may be utilizedindependently and separately from other components described herein.

Although specific features of various embodiments of the disclosure maybe shown in some drawings and not in others, this is for convenienceonly. In accordance with the principles of the disclosure any feature ofa drawing may be referenced and/or claimed in combination with anyfeature of any other drawing.

This written description uses examples to disclose various embodiments,including the best mode, and also to enable any person skilled in theart to practice the disclosure, including making and using any devicesor systems and performing any incorporated methods. The patentable scopeof the disclosure is defined by the claims, and may include otherexamples that occur to those skilled in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differ from the literal language of the claims, orif they include equivalent structural elements with insubstantialdifferences from the literal language of the claims.

1. A transport mechanism for engaging a pouch in an erect configurationat a first station of a packaging machine and transferring the pouch toa second station of the packaging machine, the transport mechanismcomprising: a carriage that is moveable between the first station andthe second station; and a grip assembly coupled to the carriage, thegrip assembly being at least partially moveable relative to the carriagebetween an engaged position for clamping the pouch in the erectconfiguration within the grip assembly, and a released position.
 2. Thetransport mechanism of claim 1, wherein the grip assembly comprises afirst grip for engaging a first side of the pouch and a second grip forengaging a second, opposed side of the pouch, and wherein the first andsecond grip are each configured to clamp the pouch in the erectedconfiguration at the first station to allow for loading of a productinto the pouch through an open end of the pouch.
 3. The transportmechanism of claim 1, wherein the carriage is moveable along a machinetransfer direction between the first station and the second station, andwherein the grip assembly is rotatable about a rotational axis that isperpendicular to the machine transfer direction.
 4. The transportmechanism of claim 1, wherein the grip assembly comprises an inner clipfor engaging an inner surface of the pouch and an outer clip forengaging an outer surface of the pouch, the outer clip being positionedbelow the inner clip.
 5. The transport mechanism of claim 4, wherein thegrip assembly further comprises a first rod rotatably coupled to thecarriage and rotatable about a first rotational axis and a second rodrotatably coupled to the carriage and rotatable about a secondrotational axis, the inner clip being coupled to the first rod and theouter clip being coupled to the second rod.
 6. The transport mechanismof claim 5, wherein, when the grip assembly transitions from thereleased position to the engaged position, the first rod rotates in afirst rotational direction and the second rod rotates in a second,opposite, rotational direction.
 7. The transport mechanism of claim 1,further comprising a controller in communication with the transportmechanism and operable to automatically control operation of at leastone of the grip assembly and the carriage.
 8. The transport mechanism ofclaim 1, wherein the first station is an erecting station that includesa landing for receiving the pouch and a pulling assembly configured toengage the pouch, the pulling assembly being moveable relative to thelanding for erecting the pouch on the landing, and wherein the secondstation is a sealing station that is configured to close the pouch. 9.The transport mechanism of claim 8, wherein the carriage is moveablealong a machine transfer direction between the first station and thesecond station, and wherein the pulling assembly comprises at least onevacuum suction cup operable to selectively engage and erect the pouch,the at least one vacuum suction cup being moveable in a directionperpendicular to the machine transfer direction.
 10. The transportmechanism of claim 1, wherein the packaging machine includes a frame atleast partially defining the first station and the second station, andwherein the transport mechanism further comprises a track extendingalong the frame from the first station to the second station, thecarriage being moveable along the track.
 11. The transport mechanism ofclaim 1, wherein the carriage is moveable along a machine transferdirection between the first station and the second station, and whereinthe grip assembly comprises a first grip and second grip each rotatablycoupled to the carriage, the first grip being offset from the secondgrip in a closing direction that is perpendicular to the machinetransfer direction, the first and second grip being moveable relative tothe carriage in the closing direction between a first configuration inwhich the first grip is spaced from the second grip and a secondconfiguration in which the first grip contacts the second grip.
 12. Thetransport mechanism of claim 1, wherein the second station comprises anadhesive applicator configured to dispense an adhesive onto an innersurface of the pouch while the grip assembly holds the pouch in theerected configuration.
 13. The transport mechanism of claim 1, whereinthe carriage is moveable along a machine transfer direction between thefirst station and the second station, and wherein the second stationcomprises a pair of pressure bars offset from one another in a closingdirection that is perpendicular to the machine transfer direction, thepressure bars each being moveable in the closing direction for sealingthe pouch.
 14. A packaging machine comprising: a first station forreceiving a container in an erect configuration; a second station spacedfrom the first station; and a transport mechanism for engaging thecontainer in the erect configuration at the first station and carryingthe container to the second station, the transport mechanism comprising:a carriage that is moveable between the first station and the secondstation; and a grip assembly coupled to the carriage, the grip assemblybeing at least partially moveable relative to the carriage between anengaged position for clamping the container in the erect configurationwithin the grip assembly, and a released position.
 15. The packagingmachine of claim 14, wherein the grip assembly comprises a first gripfor engaging a first side of the container and a second grip forengaging a second, opposed side of the container, wherein, when thefirst and second grip are each configured to hold the container in theerected configuration at the first station to allow for loading of aproduct therein through an open end of the container.
 16. The packagingmachine of claim 14, wherein the carriage is moveable along a machinetransfer direction between the first station and the second station, andwherein the grip assembly is rotatable about a rotational axis that isperpendicular to the machine transfer direction.
 17. The packagingmachine of claim 14, wherein the grip assembly comprises an inner clipfor engaging an inner surface of the container and an outer clip forengaging an outer surface of the container, the outer clip beingpositioned below the inner clip.
 18. The packaging machine of claim 17,wherein the grip assembly further comprises a first rod rotatablycoupled to the carriage and rotatable about a first rotational axis anda second rod rotatably coupled to the carriage and rotatable about asecond rotational axis, the inner clip being coupled to the first rodand the outer clip being coupled to the second rod.
 19. The packagingmachine of claim 18, wherein, when the grip assembly transitions fromthe released position to the engaged position, the first rod rotates ina first rotational direction and the second rod rotates in a second,opposite, rotational direction.
 20. A method of assembling a pouchcomprising: receiving a pouch in an erected configuration at a firststation of a packaging machine; moving a transport mechanism to thefirst station, the transport mechanism including a carriage and a gripassembly couped to the carriage; clamping the pouch within the gripassembly by moving at least a portion of a grip assembly relative to thecarriage; and carrying, by the transport mechanism, the pouch from thefirst station to a second station of the packaging machine.